Compression modular building



Aug. 6, 1968 c. FREY 3,395,502

COMPRESSION MODULAR BUILDING Filed May 17, 1965 5 Sheets-Sheet 1INVENTOR- Fl chrisr'iun frey BY *M Aug. 6, 1968 c. FREY 3,395,502

COMPRESSION MODULAR BUILDING Filed May 17, 1965 5 Sheets-Sheet 2 IINVENTOR. christian frey BY fi w-flaz u .u w, 1

g- 1968 c. FREY 3,395,502

COMPRES S I ON MODULAR BUILD ING Filed May 17, 1965 5 Sheets-Sheet 3 Fl6 4 INVENTOR. christian frey BY We -42m! 5 Sheets-Sheet 4 Filed May 17,1965 FIGT.

FIGS.

INVENTOR. christian frey Aug. 6, 1968 c FREY 3,395,502

COMPRESSION MODULAR BUILDING Filed May 17, 1965 5 Sheets-Sheet 5INVENTOR. chnsucm frey BY m am be United States Patent 3,395,502COMPRESSION MODULAR BUILDING Christian Frey, 50 7th Ave., San Francisco,Calif. 94118 Filed May 17, 1965, Ser. N0. 456,153 7 Claims. (Cl. 5273)ABSTRACT OF THE DISCLOSURE A compression modular building including aplurality of substantially identical prefabricated modular units whichhave floor, ceiling and wall portions integrally connected together anddefining a three dimensional portion, the wall panels of which areconnected to a tower supporting the modules in superposed relation. Thetower is preferably formed of a plurality of load transmitting elements,each having a height equal to the height of one module, with these loadtransmitting elements of the tower increasing progressively instructural strength from the top of the column toward the bottom.

This invention relates to architectural structures and more particularlyto multiple unit buildings of stacked modules and a novel method forconstructing the same.

In accordance with this invention, multiple unit buildings such asapartment houses, homes for the elderly,

motels, dormitories, places of business and the like are constructed ofprefabricated or substantially prefabricated modules, stacked one on topof the other, circumferentially distributed around a tower along theheight of the tower.

The tower and modules are constructed independently with the towerdesign influencing module design only if a strict mathematical designconcept is followed for grouping the modules circumferentially aroundthe tower. If this is not the case, a free grouping of the modulesaround the tower is possible. In fact, this method frees the buildingindustry from its frozen immobility by its columnbeam concept alsocalled column-grid system dictated by plan design with no escape intothe third dimension, be cause every floor will be the same once thecolumn-grid system has been decided upon.

In my case, I have developed a novel method which is the result ofanalytical logic by critically anatomizing the building physics ofpresent day highrise structures.

As major components of such structures, I identify: (1) elevators, (2)stairway, and (3) living or working area. These three major areas arenot interrelated because a living area is not an elevator, etc. The onlycommon denominator which the three major areas have are ingress andegress and that elevators and stairways are commonly identified as thecore of highrise structures, be it for apartments or places of business.

I would like todraw a parallel to clarify my method of solution for onlythat portion of the building I am interested in and as much as I see:(1) elevators and stairways as the motherbody, (2) the area for livingas the daughter modules, and (3) the area for Working as the sonmodules. Since I am only concerned with the daughter and son modules, Iwill enlarge my parallel and compare the modules with human bodies.

Now for the human body, the main physically outstanding feature is thatthe body is being carried by a vertebral column which again is composedby dorsal vertebrae.

In accordance with this invention, I imitate this biological phenomenonin architectural terms by providing a central column made of a series ofcore sections arranged end to end with each core section strong enoughtocarry a surrounding occupiable area by structural cantilever. Eachcore section may carry tensile forces from one occupiable area, and thecore section should also be computed for its compression as related toits position as a stacked module at the tower (motherbody). In otherwords, the core of the module should be able to carry all stackedmodules above its own position at the tower. The clue of this inventionis that the module design itself is not affected by the computedvertical dead and life load of other stacked modules which means thatthe bottom module of, say a twenty-five story building, is exactly thesame as e.g. the module on the nineteenth floor or at any other floor.Only the compressive strength and lateral forces imposed on its corechange, with which the building industry by its column beam system isfamiliar and has been for hundreds of years. It is also possible thatthe core of the module could be centric or eccentric. It i also possiblethat the module could be carried by one or more core systems. We are nowentering the age of the plastic design in engineering and as such it isevident in this case that a total vertibral column could reflect acurvature and two or more of such configurations could result in a treelike core structure, with themodules of different shapes at differentlocations around or in reasonable proximity of the tower (motherbody)allowing new architectual expressions in sculpture like structures.

Just as an exercise in architecture, although away from invention, thesame analytical logic is applicable to the tower body (motherbody). Thistowel-body could easily be built in a concrete slip form with standard-150 pounds of reinforcing but with modules in a free config uration andexposure (airspace). The architect might design also this t-ower in amore imaginative way of which I will illustrate an example later on forclarification of the infinite design possibilities.

Before entering into the anatomy of the stacked module, I first take acloser look at the core (dorsal vertebrae).

As explained before, this core can be an integral part of the modulewith possible compression and tension rings in this core for its ownstructural configuration. It is evident that the core could also beindependent from the module, in which case the module should have itsown core as part of the module envelope and could be identified as thesecondary module core. This secondary core should be designed largerthan the carrying core (dorsal vertebrae) or as the completed column thevertebral column.

By this design solution, it would be advantageous to prefabricate thecolumn in sections and to assemble it to required height or length atthe site to be hoisted into position. It is also possible to have theseprefabricated column units slipped into the three dimensionalprefabricated housing unit to be secured and again the module would becompleted for its dual function: (1) first to carry its own dead andlife load, and (2) to carry all dead and life loads from the modulesabove itself.

Before leaving this subject, it is understood that the total structuraldesign will be derived from the moments, shears and reactions induced bythe loads. Because of the statically indeterminate nature of thestructure be it in part (module) or in whole (completed building), thedistribution of moments, shears and reactions is affected by the shapesand sizes of the members combined with their elastic module, that istheir stifiness factors. Selection of sizes and shapes are concurrentwith the load and stress analysis. It is the purpose of the inventor tointroduce man-y new materials to be employed into the module, e.g.sandwich panels.

There are no special problems expected for the overall engineering andlateral forces can be distributed towards an access tower byinterconnecting modules and further towards the tower for-transverserigidity. The design of the core of a stacked module is basically verysimple. In our case, for illustration purposes, we have employed anhexagonal configuration. This core can be easily constructed fromstandard steel mill products. The perimeter of this core should be madeuniform in other words to have uniform modular enclosures. The mantle ofthis core will be adjusted and designed as in standard buildingpractices. In other words, to stack the units one upon the other, wepropose a simple collar design to facilitate easy stacking and standardbolting or welding systems to be employed. If the design of the core islarge enough, all these manual operations could be done from the insideof the core sections. In that case steel runs should be provided foraccess from top or bottom. It is also possible to use this core as acentral service shaft for hot and cold water, waste lines, electricalsupply, etc. It is evident that the design of the structural core can beof any design to best fit the structural solution of both the module andthe stacking or lifting principles chosen for the desired type ofbuilding involved.

The use of a plurality of prefabricated modules in this invention hasmany advantages. The module manufacturer or combined groups ofmanufacturers have substantially complete freedom in designing or havingdesigned modules for the building and the potential building tenant hasa wide freedom in selecting the housing or business unit he wants to usein a volume of space, to be leased or bought. This is also the case inhousing projects and the like.

A number of very substantial advantages are obtained by constructingbuildings in this manner. Each of the separate modules, which are to bestacked next to the motherbody, may be constructed under idealconditions in a factory where all required tools and power machinery arereadily accessible and where plumbing and electrical wiring supplies andthe like may be available in abundance. The modules may be completelyprefabricated and furnished at the factory before they are shipped totheir ultimate position at the site and stacked around the central toweras designed. When the modules are substantially completed in a factoryin this manner, the building construction can progress uniformlythroughout the year, regardless of weather conditions, leaving only theservice or central tower for construction during the normal construction season.

In some situations, as where shipping of the module to the site maypresent problems, the module may be prefabricated in small sections atthe factory and assembled at the site before it is raised, lifted,jacked or stacked into place. It is also possible to lift or stack morethan one unit module at a time or any other combination or series ofunits to be lifted, raised, jacked or stacked.

The provisions of module buildings of this type permits the use of awide variety of structural designs and materials for the individualmodules. From basic compression to stressed skim is a long range ofpossibilities. It is evident that the use of light weight buildingconstruction would be very desirable and in mass fabrication would makeit possible to use materials which were heretofore too expensive.

The construction of stacked modules for module buildings according tothis invention offers new opportunities for all those associated withthe building trade and for many concerns which have been unable tocomplete in the building construction industry.

New materials which are being developed might find their outlet andapplication here as, for example, new glass, plastics in all kinds ofcombinations, and all other unconventional materials.

The opportunity for the architect and builder to use radically new threedimensional shapes are exciting and a design challenge. Automobile,trailer, and air frame manufacturers could diversify their operationsinto this field.

Each module is preferably a self-contained prefabricated unit with itsown service elements as plumbing, wiring, heating and/or cooling unitsinstalled if so desired. The amount and type of fixtures and the likewill differ as to what purpse the prefabricated units will be used,which ranges from low-cost highrise apartment buildings to the ultimatepenthouse configuration.

Other objects and advantages of the invention will become apparent fromthe following description of several embodiments of the invention,reference being made to the attached drawings, in which:

FIG. 1 is a horizontal sectional view, somewhat schematic, and showingthe inner cores of the modules;

FIG. 2 is a horizontal plan section of a free-form tower configurationwith modules stacked in different configurations of form and stackedaround the towerbody as a solution of an infinite number of designpossibilities;

FIG. 3 is a vertical section through a stacked building composition,showing part of the towerbody, while the core system of the modules areintegrated portions of the stacked modules;

FIG. 4 is an elevation of a free-form towerbody with stacked modules ina free configuration of groupings of forms and shapes;

FIG. 5 is a somewhat schematic plan section of a core in a hexagon shapefor illustration and clarification purposes, this core having a dualfunction of carrying the module envelope and performing a portion of thetotal carrying function of all above stacked modules per design;

FIG. 6 is a vertical section through a module and illustrating the dualfunction of the core, carrying its own module and supporting through thecore all the modules above as illustrated in the modules on the leftsides of FIGS. 1 and 3 in the area denoted AA therein;

FIG. 7 is an isometric projection of the module illustrating theprotruding collar-stacking system; 7

FIG. 8 is a somewhat schematic plan section of an alternative core in agiven hexagonal shape, the dotted line indicating the so-calledsecondary core of the module, which has to be secured to the carryinginner core;

FIG. 9 is a vertical sectional view of a portion of a stack of modularbuilding units where each unit is made of a prefabricated core of FIG. 8and a prefabricated three dimensional living unit as shown in the righthand side of FIGS. 1 and 3 in the area denoted B-B therein; and

FIG. 10 is an isometric projection of one of the modules of FIG. 9, theseparate inner core column being shown in the process of being loweredinto module center.

FIGURE 1 Referring now in detail to the drawings, there is illustratedthe central tower, called above the motherbody, containing the followingcomponents: Number 1 is the enclosure of the body, which can be a simpleconcrete slip form mantle with l20150 lbs. of reinforcing. Number 2 isthe elevators, with the number of elevators depending upon the height ofthe building and the number of apartments or people (e.g., business)served. Number 3 is a dual stairway construction according to buildingcodes. Number 4 denotes corridor and entrance ways. Numbers 5, 6 and 7are three dimensional modules containing core members 3, 9, and 10,respectively, illustrated in greater detail in FIGS. 5, 6 and 7. Numbers11, 12 and 13 are the stacked modules in the same mathematicalconfiguration, with a dual core further explained in FIGS. 8, 9 and 10.Numbers 14, 15 and 16 identify these dual cores. Numbers 17 and 18illustrate optional connections between modules to create access to andenlarge a module area as required. The modular system provides airspace19 around the modules. How much airspace is required for stacking tofacilitate field engineering will differ.

FIGURE 2 This is a possible plan section for a free-form embodiment of astacked module building concept. The enclosure of the tower is calledthe motherbody. This concept contains the following components: theelevators 20; stairways 22 as required by building code, to be interiorstairways or so-called smoke towers; corridors and entrance ways 23 tostacked modules; a special module 24 with a terrace extension 25 securedto column 31; two modules 26 and 27 hooked together before being stackedinto place; a square module 28; one module 29 with two cores; andcompression cores 30, 31, 32, 33, 34 and 35 for the different modules.

FIGURE 3 FIG. 3 shows a vertical section thereof of a building similarto that shown in FIG. 1 and like reference numerals have been applied tolike parts. Additionally, these figures illustrate foundation plate 36,which may not be used under specific soil conditions; a schematicallyshown supply line 37, which can be hot and cold water, waste line,electrical and mechanical as possible by design concept; a module 38,being only a terrace configuration; two story module configures 39, and41; and bracing 42 of built-up column core, to tower. As alreadydiscussed, many more bracings may be introduced, from, for example, themodule to the module to the tower body and possibly also bridgeentranceway connections, etc.

FIGURE 4 FIG. 4 illustrates in elevation a building similar to thatshown in FIG. 2. The importance of this elevation is to show the almostcomplete freedom for three-dimensional design configurations. As alreadymentioned in the introduction, when the supporting core members aredesigned with deformed characteristics, it is possible to createtreelike structures.

This is possible because I can allow airspace, just as in a sculpture,to become part of the overall design. The penalty is relative, since Ionly have to build additional length of core members, which arefractions of the building construction.

FIGURE 4 is similar to FIG. 3 and like reference numerals have been usedto identify like parts.

Additionally, this figure illustrates typical end column bracings 42 andhalf spheres 43 and 44 and a combination of the half spheres.

FIGURES 5, 6 and 7 These figures illustrate the stacking of the moduleson the left hand sides of FIGS. 1 and 3 in the area indicated A-Atherein. We know that the Russians have and are employing the concretebox module system. This system might be qualified as the brute forceapproach and is in fact an approach in which the box was a slice from astandard high-rise building concept. This slice, which formerly Was thetypical column-beam system, has now been realized into a heavy concretebox. This box by the limitations of concrete had to be over-designedwith reinforcing, even with prestressing systems, to allow it to be usedas a building block. Because of the tremendous dead load and fieldengineering problems, the sizes of these blocks had to be limited andonly combinations of blocks would result in an adequate area for livingand sleeping. Habitat 67, in Montreal proposes a similar feat for a 24story complex of concrete boxes. The cost was so prohibitive thatfinancing was impossible. With government help and a reduction to a 12story system, they will try again. The brute force, as is probablyalready understood, has to be carried by all the walls of the box ormodule.

As discussed before, I call the module the daughter and the core thedorsal vertebrae. My invention departs completely from the philosophy ofbrute force because the walls of my modules are non-load bearing walls.The whole dead and live load configurations, as they will occur, areconcentrated towards a predesigned area, be it centered or eccentric. Inthis area we receive and distribute by simple compression practices allthe dead and live loads as a hollow column concept, made from standardsteel mill products. There will not the savings in material but themodule itself has been freed from its frozen environment and can now bemass produced. Here is the enormous savings in time and money.

These figures illustrate a wall section 6 continuing into a ceilingsystem. The floor by necessity is a cantilevered construction, securedto the all carrying core portion. This core 9 can be of standardstructural steel, or with sheet metal or any other combination. Inschematics is shown the different strength of this core in the mantlethickness differences of this core, the compressive strength decreasingprogressively from module to module as the height of the buildingincreases. A simple collar design, which can be bolted or welded fromthe inside according to engineering data, is illustrated. As also shown,this system of enclosure has a resemblance to a monoque system, whichmight well be the case if so desired.

Also illustrated are metal runs for access 45. If the design of thecentral core allows it, all kind of piping 46, mechanical andelectrical, can be incorporated. The basic simple collar design isillustrated at 47 FIGURES 8, 9 and 10 Here the core system hastemporarily been divorced from the module to be stacked into position atthe tower and as such can be prefabricated. As discussed before, themodule has non-bearing walls and as such could not be stacked and wouldbe useless for my purpose.

Here the parallel with the human body becomes clear and makes sense. Ourbody without the vertebral column would collapse and just missing adorsal vertebrae would immobilize the whole body structure, as such thenwe have the envelope, the module with a secondary core 50 to completethe envelope. In each module regardless of the design configuration, acarrying core (dorsal vertebrae) has to support the module body, andX-members of such stacked core members then become the vertebral column,in this case the completed structural column as illustrated in FIGS. 3and 4.

Two cores 15 and 50, prefabricated above and on the three dimensionalbuilding respectively, are illustrated, which have to be connected perdesign, and it is just a matter of schematics how I will make this coreand in what material with or without prestressing or poststressing.

For illustration purposes, the free space 51 between the modules hasbeen overdesigned and it is easily understood that this airspace can bedecreased to any size required and allowable by sensitive engineeringand production processes.

While specific embodiments of the invention have been illustrated anddescribed in detail herein, it is obvious that many modificationsthereof may be made without departing from the spirit and scope of theinvention.

I claim:

1. The method of making a building of predetermined height whichcomprises:

(A) erecting an access column on, the ground with said column having aplurality of exterior openings therein at progressive elevations abovethe ground and a vertically extending access passageway therein forhuman passage from the ground to said exterior openings,

(B) prefabricating a plurality of building units (1) with each of saidunits having a height which is an integral multiple of the distancebetween said elevations of said column, and

(2) with each of said units having (a) a three dimensional portiondefining a volume of occupiable space, and

(b) a support portion on which said three dimensional portion ismounted,

(3) the three dimensional portions of all of said building units havingsubstantially similar compressive strengths, and

(4) the support portions of said building units having ditferentcompressive strengths which form a series of progressively greatercompressive strengths,

(C) forming said building units into a plurality of stacks of buildingunits by (1) placing one of said building units on top of another one ofsaid building units which has a support portion of greater compressivestrength than said one building unit with the support portions of saidbuilding units in load transmitting relation with each other, and

(2) progressively placing on top of said building units in a similarmanner additional ones of said building units which have supportportions of progressively decreasing compressive strength, and

(D) connecting each of said stacks of building units to said column toimpart lateral stability thereto.

2. The method of making a building which comprises:

(A) prefabricating a plurality of three dimensional modular buildingunits with all of said units having similar compressive strengths,

(B) prefabricating a plurality of compression units having progressivelygreater compressive strengths,

(C) attaching one of said modular units to each of said compressionunits, and

(D) stacking said compression units upon each other with the compressionunits of greater compressive strength underneath and supporting thecompression units of lesser compressive strength.

3. The method of making a building which comprises:

(A) erecting an access column on the ground with said column having aplurality of exterior openings therein at progressive elevations abovethe ground and a vertically extending access passageway therein forhuman passage from the ground to said exterior openings,

(B) prefabricating a plurality of three dimensional modular buildingunits with all of said units having similar compressive strengths,

(C) prefabricating a plurality of compression units having progressivelygreater compressive strengths with each of said compression units havinga length which is an integral multiple of the distance between saidelevations of said column,

(D) attaching one of said modular units to each of said compressionunits,

(E) stacking said compression units in a plurality of stacks adjacent tosaid column with the compression units of greater compressive strengthin each of said stacks underneath and supporting the compression unitsof lesser compressive strength in each of said stacks, and with each ofsaid modular units in said stacks communicating with one of saidexterior openings, and

(F) connecting each of said stacks of compression units to said columnto impart lateral stability thereto.

4. A multistory building which comprises:

(A) a plurality of modular building units with each of said modularunits having a support portion and a three dimensional portion mountedon said support portion projecting laterally therefrom and defining avolume of occupiable space, and

(B) positioning means positioning said modular building units in avertical stack with said support portions of said building unitsconnected together end to end for transmission of compressive loads fromupper building units in said stack to lower building units in said stacksolely through said support portions.

5. The building of claim 4 characterized further in that each of saidmodular building units has a center of mass, and said center of mass ofeach of said building units lies within said support portion of thatbuilding unit.

6. The building of claim 4 in which the compressive strength of each ofsaid support portions in said stack is greater than the compressivestrength of the support portion above it in said stack.

7. A multistory building which comprises:

(A) an access column mounted on the ground and having a plurality ofexterior openings therein at progressive elevations above the ground anda vertically extending access passageway therein for human passage fromthe ground to said exterior openings,

(B) a plurality of modular building units with each of said modularbuilding units having a support portion and a three dimensional portionmounted on said support portion and projecting laterally therefrom anddefining a volume of occupiable space,

(C) said modular building units being connected to each other in aplurality of vertically extending stacks of building units adjacent tosaid column with each of said stacks of building units including aplurality of said building units communicating with said exterioropenings in said column and with the support portions thereof connectedtogether end to end for transmission of compressive loads from upperbuilding units to lower building units in said stack solely through saidsupport portions, and

(D) generally horizontally extending structural members connecting saidcolumn to the support portion of at least one of said building unitsadjacent to the top of each of said stacks for imparting lateralstability to said stacks.

References Cited UNITED STATES PATENTS 2,128,463 8/1938 Kaufman 527263,289,382 12/1966 Van der Lely 5279 X FOREIGN PATENTS 827,408 1952Germany. 572,894 1958 Italy. 1,280,768 1961 France.

OTHER REFERENCES Interbuild, vol. 6, No. 3, p. 10, March 1959. PopularMechanics, p. 113, December 1959.

JOHN E. MURTAGH, Primary Examiner.

